AN inquest has been opened into the death of a 28-year-old worker at a cement plant in Warwickshire.

Peter Reynolds is believed to have fallen more than 30ft to his death at the Cemex plant, in Lawford Road, Rugby, in January 2008.

A hearing at Leamington yesterday heard Mr Reynolds, who was from Brownsover, in Rugby, was working inside one of the upper mixers in a four storey bypass dust machine on the day he died – Tuesday January 15 2008.

The inquest was told that problems had arisen when one mixer had become blocked but another mixer above continued to dump material below causing a ‘‘mechanical overload’’.

It is believed hot gases and steam then caused a chemical explosion.

During the inquest, a statement by team leader Nigel Crockford, was read out which explained there had been a similar explosion in the machine before after the mixer doors opened under pressure because of a blockage.

The statement read: “I was covered from head to toe in dust and had burns to my hands and eyes. The door was released under pressure – it went bang.

“I tried to find my way out – I was completely blind. I got to the external stairs. I had a burning sensation on my face. I wasn’t sure if it was alkaline material.”

He explained that blockages were becoming “troublesome” but that the situation had improved following a refurbishment.

Worker Stuart Andrews, who would regularly clean the machine, said he has cleared at least 15-20 blockages in the past five years.

Describing a blockage, he said: “Mixer blades weren’t where they should be and when the dust and water didn’t mix properly.

“It builds up into thick lumps. It would take six to eight hours to clear out with two men.”

Mr Reynolds had worked for the company for about eight years.

It was the second death to have happened at the plant in recent years. A 34-year-old contractor from Sheffield had been crushed in 2006.